FIELD OF THE INVENTION
[0001] The present invention relates to a method and apparatus for automating a routine
operation of an electronically controlled hydraulic-powered machine, the apparatus
being mounted on the hydraulic-powered machine such as construction machines and the
like to have the hydraulic-powered machine perform its simple routine operation repetitively
by automation, which routine operation is frequently required to be performed in practice.
DESCRIPTION OF THE PRIOR ART
[0002] As for a control system of a hydraulic-powered machine such as construction machines
and the like comprising power shovels and wheel-type loaders, further advances in
electronic engineering and hydraulic engineering in recent years make it possible
to replace a conventional mechanical control system of the hydraulic-powered machine
with an electronically controlled system in which a control lever 1 of the machine
is moved by an operator of the machine in operation to the extent of a desired amount
as shown in Fig. 1, so that the desired amount of motion of the control lever 1 is
converted into an electric signal on the basis of which the hydraulic-powered machine
is controlled. Namely, as shown in Fig. 1, in an electric control unit 2, the desired
amount of motion of the control lever 1 operated by the operator is converted into
the electric signal which is issued from the electric control unit 2 to an electronic
controller 3. Then, in the electronic controller 3, the electric signal is converted
into another signal issued to an electronically controlled hydraulic valve 4. Consequently,
in response to the another signal, the electronically controlled hydraulic valve 4
permits a hydraulic pump 6 to supply a predetermined amount of pressure oil to a hydraulic
actuator 5 through passages 7a or 7b, which amount of pressure oil corresponds to
the another signal.
[0003] Such conventional electronically controlled system having the above construction
permits the operator of the hydraulic-powered machine to conduct a delicate operation
of the machine, which delicate operation can not be performed hitherto.
[0004] As described above, the conventional electronically controlled system shown in Fig.
1 permits the operator of the hydraulic-powered machine to perform such delicate operation.
However, in this conventional system, operation of the hydraulic-powered machine is
manually conducted by the operator of the machine through the manually controlled
lever 1. Particularly, for example, in a digging operation of a wheel-type hydraulic-powered
loader H, as shown in Fig. 2A, first of all, the loader is moved forward in a condition
in which a bucket B of the loader H is oriented toward a pile of earth E, so that
the bucket B penetrates the pile of earth E. After that, the bucket B is gradually
moved to have its opening oriented upward as the loader H moves further forward. Namely,
the bucket B is filled with earth E by such upward and forward motion. Then, as shown
in Fig. 2B, the loader H travels to a desired place. When the loader H reaches the
desired place, the opening of the bucket B is oriented downward to unload the earth
E onto the place. After that, the loader H is moved slightly rearward to complete
its digging operation.
[0005] As described above, in the conventional earth digging operation conducted by the
wheel-type hydraulic-powered loader H, several tens of repetitive routine operations,
i.e., repetitive earth digging and unloading operations are required. Therefore, the
operator of the loader H is overburdened with such a tiresome repetition of the same
operations.
SUMMARY OF THE INVENTION
[0006] Under such circumstances, the present invention was made. Consequently, it is an
object of the present invention to provide a method and apparatus for automating a
routine operation of an electronically controlled hydraulic-powered machine, the apparatus
being mounted on the hydraulic-powered machine to have the hydraulic-powered machine
perform repetitively its simple routine operation by automation in safety, which routine
operation is frequently required to be performed.
[0007] It is another object of the present invention to provide a method and apparatus for
automating a routine operation of an electronically controlled hydraulic-powered machine,
the apparatus being mounted on the hydraulic-powered machine to have the hydraulic-powered
machine perform an effective loading operation of a preset amount of load.
[0008] In accordance with a first aspect of the present invention, the above objects of
the present invention are accomplished by providing:
[0009] In a method for automating a routine operation of an electronically controlled hydraulic-powered
machine in which a motion of a control lever operated by an operator is converted
into an electric signal which is issued to an electronic controller which in turn
issues a control signal on the basis of the electric signal to control the hydraulic-powered
machine, the improvements which comprises:
issuing a first signal for causing a working equipment mounted on the hydraulic-powered
machine to perform a routine operation corresponding to a specific motion of the control
lever operated by the operator;
summing in calculation the first signal and a mode signal in an operation automating
controller after the first signal and the mode signal are received by the operation
automating controller, the mode signal being issued from a switchboard to the operation
automating controller for determining a mode of the routine operation; and
issuing an electric signal from the operation automating controller to the electronic
controller.
[0010] In accordance with a second aspect of the present invention, the objects of the present
invention are accomplished by providing:
[0011] In a method for automating a routine operation of an electronically controlled hydraulic-powered
machine in which a motion of a control lever operated by an operator is converted
into an electric signal which is issued to an electronic controller which in turn
issues a control signal on the basis of the electric signal to control the hydraulic-powered
machine, the improvements which comprises:
issuing a first signal for causing a working equipment mounted on the hydraulic-powered
machine to perform a routine operation corresponding to a specific motion of the control
lever operated by the operator;
summing in calculation the first signal, a preset data signal and sensor data signal
in an operation automating controller which issues a resultant data, the preset data
signal being issued from a switchboard for previously selectively determining a target
workload, and the sensor data signal being issued from a sensor mounted on the working
equipment for measuring a weight of a load such as earth and the like with which the
working equipment is loaded;
comparing the resultant data with a predetermined data;
issuing a playback signal until the resultant data coincides with the predetermined
data, to cause the working equipment to repetitively perform the routine operation
by automation; and
stopping issuance of the playback signal when the resultant data coincides with the
predetermined data, to cause the working equipment to stop the routine operation thereof.
[0012] In accordance with a third aspect of the present invention, the objects of the present
invention are accomplished by providing:
In an apparatus for automating a routine operation of an electronically controlled
hydraulic-powered machine in which a motion of a control lever operated by an operator
of the hydraulic-powered machine is converted into an electric signal which is issued
to an electronic controller which in turn issues a control signal on the basis of
the electric signal to control the hydraulic-powered machine, wherein, the improvement
comprises the apparatus further including:
a control lever signal issuing means for issuing a control lever signal which causes
a working equipment mounted on the hydraulic-powered machine to perform a routine
operation corresponding to a specific motion of the control lever operated by the
operator;
a switchboard for selectively determining a mode of the routine operation to issue
a mode signal; and
an operation automating controller for receiving the control lever signal and the
mode signal to sum these signals in calculation to issue a resultant electric signal
to the electric controller.
[0013] In accordance with a fourth aspect of the present invention, the objects of the present
invention are accomplished by providing:
In the apparatus for automating the routine operation of the electronically controlled
hydraulic-powered machine, as set forth in the third aspect, wherein:
the apparatus further comprises a sensor for measuring a weight of a load such as
earth and the like with which the working equipment mounted on the hydraulic-powered
machine is loaded, the sensor being mounted on the working equipment to issue a loading
weight data signal to the operation automating controller, which loading weight data
signal corresponds to a loading weight of the working equipment.
[0014] In accordance with a fifth aspect of the present invention, the objects of the present
invention are accomplished by providing:
[0015] In the apparatus for automating the routine operation of the electronically controlled
hydraulic-powered machine, as set forth in the third or fourth aspect, wherein the
operation automating controller comprises:
a memory means for storing the control lever signal providing an instruction value;
an operation-range displaying unit for displaying an operation range of the working
equipment;
a preset cycle time displaying unit for displaying a preset cycle time of the instruction
value;
a residual time displaying unit for displaying a residual time or residual memory
area in the memory means;
a warning unit for giving a warning before the specified routine operation starts;
and
a played-back operation number displaying unit for displaying the number of the routine
operations having been repetitively played back.
[0016] Effects of the present invention having the above aspects are as follows:
(1) Only by operating the control lever and depressing an operation-mode button of
the switchboard, it is possible for the operator to have the working equipment of
the hydraulic-powered machine perform repetitively the frequently required simple
routine operation by automation. Consequently, the present invention can releases
the operator from a tiresome repetition of work;
(2) The present invention makes it possible to accurately sum the loading weight of
the load such as earth and the like with which the working equipment is loaded. Consequently,
the present invention can eliminates variation in loading weight due to operator's
factor or personal factor to realize an effective loading operation with respect to
a predetermined load;
(3) According to the present invention, it is possible for the second operator to
previously know the routine operation of the working equipment when he playbacks the
motion of the control lever having been stored by the first operator, it is possible
for the second operator to have the working equipment playback repetitively the routine
operation in safety;
(4) According to the present invention, since the operator can confirm the cycle time
of the routine operation and also easily measures the cycle time of another routine
operation, it is possible for the operator to easily conduct the operating control
of the working equipment;
(5) According to the present invention, since the operator can confirm the residual
time stored in the memory means, there is no fear that the residual time expires during
a storage operation of the memory means. Consequently, it is possible to prevent error
in storage operation from occurring;
(6) In case that the operator has the working equipment playback the routine operation
thereof, the operator knows the following action of the working equipment. Consequently,
in case that the following action of the working equipment is dangerous to the other
workers around the hydraulic-powered machine on which the working equipment is mounted,
it is possible for the operator to preset the warning switch so as to give a warning
to the other workers several seconds earlier than before the working equipment.starts
the following dangerous action, so that the present invention prevents accidents from
occurring; and
(7) According to the present invention, it is possible for the operator to confirm
the number of the routine operation having been repetitively played back. Consequently,
by confirming a weight of the load with which a bucket of the working equipment is
loaded, it is possible for the operator to estimate a total amount of workload having
been done during the routine operation repetitively played back.
[0017] The above objects, additional objects, additional embodiments and advantages of the
present invention will be clarified to those skilled in the art hereinbelow with reference
to the following description and accompanying drawings illustrating preferred embodiments
of the present invention according to principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018]
Fig. 1 is a schematic block diagram of a conventional apparatus for automating a routine
operation of the electronically controlled hydraulic-powered machine;
Figs. 2A, 2B and 2C are schematic side views of the wheel-type hydraulic-powered loader,
illustrating earth loading/unloading operation of the loader;
Fig. 3 is a schematic block diagram of a first embodiment of an apparatus of the present
invention for automating a routine operation of an electronically controlled hydraulic-powered
machine;
Fig. 4 is a flowchart of the operation performed by the first embodiment of the present
invention shown in Fig. 3;
Fig. 5 is a schematic block diagram of a second embodiment of the apparatus of the
present invention for automating the routine operation of the electronically controlled
hydraulic-powered machine;
Fig. 6 is a flowchart of the operation performed by the second embodiment of the present
invention shown in Fig. 5;
Fig. 7 is a schematic block diagram of a third embodiment of the apparatus of the
present invention for automating the routine operation of the electronically controlled
hydraulic-powered machine; and
Fig. 8 is an electric circuit diagram of the operation automating controller employed
in the third embodiment of the apparatus of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Hereinbelow, preferred embodiments of the present invention will be described in
detail with reference to the accompanying drawings (Figs. 3 to 9).
[0020] Fig. 3 is a schematic block diagram of a first embodiment of an apparatus of the
present invention for automating a routine operation of an electronically controlled
hydraulic-powered'machine. A flowchart of operation performed by the first embodiment
of the apparatus of the present invention shown in Fig. 3 is shown in Fig. 4.
[0021] In the drawings: the reference numeral 11 denotes a control lever of a working equipment,
for example such as that 20 shown in Fig. 5, the working equipment being mounted on
the hydraulic-powered machine; and 12 an electric control unit for converting a motion
of the control lever 11 operated by an operator into an electric signal V
1 which is issued from the electric control unit 12 to an operation automating controller
13
1. The controller 13
1 issues a signal V
2 to an electronic controller 15 upon receipt of the electric signal V
1. In accordance with the signal V
2 issued from the operation automating controller 13
1, the electronic controller 15 issues an electric signal V
3 for controlling an electronically controlled hydraulic valve 16. Through the thus
controlled hydraulic valve 16, pressure oil supplied by a hydraulic pump 19 passes
through passage 17a or 17b so as to be supplied to a hydraulic actuator 18 such as
hydraulic motors and hydraulic cylinders, whereby an actuating rod 18a of the hydraulic
actuator 18 is actuated.
[0022] In the drawings, the reference numeral 14
1 denotes a switchboard for selectively determining a mode M
1,
M2, M
3, ..., M of the automated routine operation of the working equipment mounted on the
hydraulic-powered machine.
[0023] In operation, the operator of the working equipment selects a mode of the automated
routine operation of the working equipment by pushing a push button of the switchboard
14
1 so that the switchboard issues a signal for having the working equipment perform
a desired frequently-required routine operation, for example such as a digging operation
when the push button for the mode M
1 is pushed or a earth discharging operation when the push button for the mode M
2 is pushed. Under such circumstances, when the operator pushes a push button lla of
the control lever 11, the working equipment start the routine operation by automation,
the routine operation being specified by pushing the push button of the switchboard
14
1.
[0024] In case that the automated routine operation performed by the working equipment mush
be corrected, it is necessary for the operator to operate the control lever 11 of
the working equipment. When the operator operates the control lever 11 of the working
equipment in operation, the electric control unit 12 issues an electric signal to
be summed in calculation.
[0025] Now, operation of the apparatus of the present invention for automating the routine
operation of the working equipment of the hydraulic-powered machine will be described
with reference to a flowchart shown in Fig. 4.
[0026] The flowchart shown in Fig. 4 comprises steps S01, S02, S03, S04 and S05. In the
step S01, operation of the working equipment starts. Then, in the step S02, the operator
pushes a desired one of the push buttons or mode buttons M
1, M
2, M
3, ..., M
n of the switchboard 14
1 to select a desired mode of the routine operation. After that, in the step S03, the
operator pushes a push button 11a of the control lever 11 of the working equipment
to have the working equipment perform the routine operation by automation. In the
step S04, in order to correct the automated routine operation performed by the working
equipment, the operator suitably operates the control lever 11 of the working equipment
to have the electric control unit 12 issue an electric signal which is added to an
automating signal in the step S05, which automating signal has the working equipment
perform the routine operation by automation.
[0027] Now, a second embodiment of the apparatus of the present invention for automating
the routine operation of the working equipment will be described with reference to
Figs. 5 and 6. Incidentally, like reference numerals apply to similar parts through
the first and the second embodiment of the present invention to avoid redundancy in
description.
[0028] In Fig. 5: the reference numeral 20 denotes the working equipment, for example such
as electronically controlled hydraulic-powered digging machines and the like; and
21 a bucket employed in the working equipment 20. The working equipment or digging
machine 20 is controlled in operation by an electronic controlling system of the second
embodiment of the present invention shown in Fig. 5. On the other hand,, mounted on
the bucket 21 of the working equipment or digging machine 20 is a sensor 22 for measuring
a loading weight of a load with which the bucket 21 is loaded.
[0029] The second embodiment of the apparatus of the present invention shown in Figs. 5
and 6 differs from the first embodiment of the present invention shown in Figs. 3
and 4 in the following points:
[0030] Namely, in the second embodiment of the present invention, as shown in Fig. 5, the
operation automating controller 13
2 is electrically connected with the switchboard 14
2 which is provided with a plurality of workload switch buttons 14a and a plurality
of data processing display units 14b, through which workload switch buttons 14a a
workload is preset. Consequently, when the operator of the working equipment or digging
machine 20 pushes a desired one of the workload switch buttons 14a, the thus specified
workload is stored in a data area of the operation automating controller 13
2. Further inputted to the operation automating controller 13
2 each cycle of the routine operation performed by the working equipment or digging
machine 20 is-an actual workload data signal issued from the sensor 22 mounted on
the bucket 21 of the working equipment or digging machine 20. Such actual workload
data is accumulated in the operation automating controller 13
2.
[0031] Namely, in the operation automating controller 13
2, the actual workload data signal issued from the sensor 22 each cycle of the routine
operation performed by the working equipment or digging machine 20 is summed up to
produce a summed data signal which is compared with the predetermined data signal.
Until the summed data signal coincides in amount with the predetermined data signal,
a playback signal is issued from the operation automating controller 13
2 to the electronic controller 15 to have the electronically controlled hydraulic valve
16 permit the hydraulic pump 19 to supply the pressure oil to the hydraulic actuator
18 through the passage 17a or 17b, so that the actuator 18 performs repetitively its
actuating operation, whereby the routine operation of the working equipment or digging
machine 20 is repetitively performed by automation.
[0032] In operation, when the summed data signal coincides in amount with the predetermined
data signal, issuance of the playback signal stops to stop the repetitive routine
operation of the working equipment or digging machine 20. At the same time, the display
units 14b display a condition in which the summed data signal coincides in amount
with the predetermined data signal. Incidentally, in Fig. 5, the reference numeral
13a denotes a starting switch of the operation automating controller 1
32
.
[0033] The operation described above is shown in the flowchart shown in Fig. 6.
[0034] In accordance with the second embodiment of the apparatus of the present invention,
it is possible for an unskilled operator to have the working equipment or digging
machine 20 perform accurately and effectively the routine operation which is hitherto
performed only by a skilled operator.
[0035] Fig. 7 is a schematic block diagram of a third embodiment of the apparatus of the
present invention for automating the routine operation of the electronically controlled
hydraulic-powered machine.
[0036] The followings should be considered in automating the routine operation which is
frequently and repetitively required in practice: namely
(1) When the routine operation stored in the memory means by an operator is played
back by another operator, it is very dangerous to play back such routine operation
in a condition in which the another operator does not recognize the type of the routine
operation performed by the working equipment;
(2) It is necessary to measure the cycle time of the routine operation performed by
the working operation;
(3) When an amount of processes of the routine operation to be stored in the memory
means exceeds a capacity of the memory means, error occurs in storage operation of
the apparatus of the present invention;
(4) When the routine operation performed by the working equipment is dangerous to
the other workers, it is necessary for the operator of the working equipment to give
a warning to the other workers before the routine operation is performed; and
{5) It is necessary for the operator of the working equipment to know the number of
the routine operation having been repetitively performed.
[0037] In view of the above considerations, the third embodiment of the apparatus of the
present invention is provided. Incidentally, like reference numerals apply to similar
parts throughout the first, second and also the third embodiment of the present invention
to avoid redundancy in description.
[0038] The third embodiment of the present invention shown in Figs. 7 and 8 differs from
the first embodiment of the present invention shown in Figs. 3 and 4 in the following
points. In the third embodiment of the present invention shown in Figs. 7 and 8, inputted
to the operation automating controller 13
3 are: the electric signal V
1 issued from the electric control unit 12; a switchboard signal issued from a dial-type
switchboard 14
3 provided with a dial 14 ; a warning signal issued from a warning switch 30; and a
display switching panel signal issued from a dial-type display switching panel 31
provided with a dial 31a. In addition, as shown in Fig. 7, the third embodiment of
the present invention is provided with an external display unit 32.
[0039] Fig. 8 is an electric circuit diagram of the operation automating controller 13
3 employed in the third embodiment of the apparatus of the present invention, illustrating
an internal construction of the operation automating controller 13
3.
[0040] In operation, when the operator sets the dial 1.4c of the switchboard 14
3 at a position T as shown in Fig. 7 and operates the control lever 11 of the working
equipment, as shown in Fig. 8, the electric signal V
i corresponding to a motion of the control lever 11 operated by the operator is issued
from the electric control unit 12 to the operation automating controller 13
3 in which the electric signal V
1 is converted into a digital signal through an A/D converter. The thus converted digital
signal is inputted to a CPU through which the digital signal is processed to produce
a processed signal. The thus processed signal is then inputted to a D/A converter
so as to be converted into an analog signal or electric signal V
2. At the same time, the processed signal is also stored in a RAM. On the other hand,
the electric signal V
2 issued from the D/A converter is supplied to the electronic controller 15 which in
turn issues another electric signal V
3 to control the electronically controlled hydraulic valve 16, so that the actuating
rod 18a of the hydraulic actuator 18 is actuated as described above.
[0041] In the above operation, when the operator pushes the button 30a of the warning switch
30 in a condition in which the control lever 11 of the working equipment is operated
by the operator, a warning issuance signal is stored in the operation automating controller
I3
3.
[0042] Then, when the dial 31a of the display switching panel 31 is set at a position of
"operation range" before the motion of the control lever 11 having been stored is
played back, a motion of the working equipment is displayed in the display unit 9.
In this case, if necessary, it is al-so possible for the display unit 9 to display
the motion of the working equipment two times faster than original. On the other hand,
when the dial 14c of the switch panel 14
3 is set at the position T, the motion of the control lever 11 of the working equipment
is stored in the RAM of the operation automating controller 13
3 at predetermined time intervals. After that, the number of such storage operation
performed in the RAM of the operation automating controller 13
3 is counted until the dial 14c reaches a position "off" or a position "P", so that
the thus counted total number of the storage operation is multiplied by the predetermined
time to obtain a product. Such product of the total number of the storage operation
and the predetermined time constitutes a time a cycle or "cycle time" of the routine
operation performed by the working equipment. Consequently, by setting the dial 31a
of the display switching panel 31 at a position of the above "cycle time", it is possible
for the operator to have the display unit 14b display the "cycle time".
[0043] After that, when the operator sets the dial 14c of the switchboard 14
3 at the position P and then pushes the push button lla of the control lever 11 of
the working equipment, a solenoid 33 of the operation automating controller 13
3 is electrically energized to cause a movable contact 34 to be brought into contact
with a fixed contact 35. As a result, as shown in Fig. 8, the electric signal V
1 stored in the RAM of the operation automating controller 13
3 is processed in the CPU and then converted into the signal V
2 through the D/A converter, so that the signal V
2 is supplied to the electronic controller 15 through the contacts 34, 35. Consequently,
the electronic controller 15 issues the electric signal V
3 to control the electronically controlled hydraulic valve 16, so that the actuating
rod 18a of the hydraulic actuator 18 is actuated as described above.
[0044] In this case, the external display unit 32 gives a warning to the other workers around
the working equipment before the operator pushes the button 30a of the warning switch
30.
[0045] On the other hand, in storage operation of another motion of the control lever 11
of the working equipment different from the motion of the lever 11 previously stored,
in order to confirm a residual time or residual memory area of the RAM of the operation
automating controller 13
3, the operator sets the dial 31a of the display switching panel 31 at a position of
a "residual time". As a result, a memory area having been already used is subtracted
from the total memory area of the RAM to give the residual memory area or residual
time which is displayed in the display unit 14b. When the residual time or residual
memory area of the RAM of the operation automating controller 13
3 reduces to a predetermined amount in operation, a warning is issued by reducing intervals
in energizing time of intermittently lightened warning lamp or by giving a warning
sound issued from buzzers and the like.
[0046] In addition, the operation automating controller 13
3 is provided with a counter for counting the number of the routine operation having
been repetitively played back. In use, when the operator sets the dial 31a of the
display switching panel 31 at a position of the "number of the routine operation having
been played back", the number of the routine operation having been played back by
the working equipment by automation is displayed in the display unit 14b. As a result,
on the basis of a capacity of the bucket of the working equipment and the number of
the routine operation displayed in the display unit 14b. it is possible for the operator
to estimate the total workload accomplished by the working equipment by automation
or played-back operation performed by the working equipment.